Sprinkler Assembly

ABSTRACT

The present invention includes an improved sprinkler design having a magnetic sensing system for determining the position of the riser nozzle, a waterproofed motor housing and related cables, configurable sprinkler body compartments, and a pilot valve with a check valve assembly, both of which are located within the sprinkler body.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/861,603 filed Jan. 3, 2018 entitled Sprinkler Assembly, which is acontinuation of U.S. patent application Ser. No. 15/456,234 filed Mar.10, 2017 entitled Sprinkler Assembly, now U.S. Pat. No. 9,889,458 issuedFeb. 13, 2018; which is a continuation of U.S. patent application Ser.No. 15/004,643 filed Jan. 22, 2016 entitled Sprinkler Assembly, now U.S.Pat. No. 9,623,431 issued Apr. 18, 2017; which is a continuation of U.S.patent application Ser. No. 14/299,811 filed Jun. 9, 2014 entitledSprinkler Assembly, now U.S. Pat. No. 9,242,255 issued Jan. 26, 2016;which is a continuation of U.S. patent application Ser. No. 13/718,881filed Dec. 18, 2012 entitled Sprinkler Assembly, now U.S. Pat. No.8,746,591 issued Jun. 10, 2014; which is a continuation of U.S. patentapplication Ser. No. 12/608,915 filed Oct. 29, 2009 entitled SprinklerAssembly, now U.S. Pat. No. 8,444,063 issued May 21, 2013; which is acontinuation of U.S. patent application Ser. No. 11/303,328 filed Dec.15, 2005 entitled Sprinkler Assembly, now U.S. Pat. No. 7,631,813 issuedDec. 15, 2009; which claims priority to U.S. Provisional ApplicationSer. No. 60/637,342 filed Dec. 17, 2004 entitled Sprinkler Assembly; allof which are hereby incorporated by reference herein in theirentireties.

FIELD OF THE INVENTION

This invention relates generally to irrigation sprinklers. Morespecifically, this invention relates to a motorized irrigation sprinklerhaving an improved body compartment design with magnetic sprinkler headsensing.

BACKGROUND OF THE INVENTION

Sprinkler systems for turf irrigation are well known. Typical systemsinclude a plurality of valves and sprinkler heads in fluid communicationwith a water source, and a centralized controller connected to the watervalves. At appropriate times the controller opens the normally closedvalves to allow water to flow from the water source to the sprinklerheads. Water then issues from the sprinkler heads in predeterminedfashion.

There are many different types of sprinkler heads, includingabove-the-ground heads and “pop-up” heads. Pop-up sprinklers, thoughgenerally more complicated and expensive than other types of sprinklers,are thought to be superior. There are several reasons for this. Forexample, a pop-up sprinkler's nozzle opening is typically covered whenthe sprinkler is not in use and is therefore less likely to be partiallyor completely plugged by debris or insects. Also, when not being used, apop-up sprinkler is entirely below the surface and out of the way.

The typical pop-up sprinkler head includes a stationary body and a“riser” which extends vertically upward, or “pops up,” when water isallowed to flow to the sprinkler. The riser is in the nature of a hollowtube which supports a nozzle at its upper end. When the normally-closedvalve associated with a sprinkler opens to allow water to flow to thesprinkler, two things happen: (i) water pressure pushes against theriser to move it from its retracted to its fully extended position, and(ii) water flows axially upward through the riser, and the nozzlereceives the axial flow from the riser and turns it radially to create aradial stream. A spring or other type of resilient element is interposedbetween the body and the riser to continuously urge the riser toward itsretracted, subsurface, position, so that when water pressure is removedthe riser assembly will immediately return to its retracted position.

The riser assembly of a pop-up or above-the-ground sprinkler head canremain rotationally stationary or can include a portion that rotates incontinuous or oscillatory fashion to water a circular or partly circulararea, respectively. More specifically, the riser of the typical rotarysprinkler includes a first portion (e.g. the riser), which does notrotate, and a second portion, (e.g. the nozzle assembly) which rotatesrelative to the first (non-rotating) portion.

The rotating portion of a rotary sprinkler riser typically carries anozzle at its uppermost end. The nozzle throws at least one water streamoutwardly to one side of the nozzle assembly. As the nozzle assemblyrotates, the water stream travels or sweeps over the ground.

The non-rotating portion of a rotary sprinkler riser assembly typicallyincludes a drive mechanism for rotating the nozzle. The drive mechanismgenerally includes a turbine and a transmission. The turbine is usuallymade with a series of angular vanes on a central rotating shaft that isactuated by a flow of fluid subject to pressure. The transmissionconsists of a reduction gear train that converts rotation of the turbineto rotation of the nozzle assembly at a speed slower than the speed ofrotation of the turbine.

During use, as the initial inrush and pressurization of water enters theriser, it strikes against the vanes of the turbine causing rotation ofthe turbine and, in particular, the turbine shaft. Rotation of theturbine shaft, which extends into the drive housing, drives thereduction gear train that causes rotation of an output shaft located atthe other end of the drive housing. Because the output shaft is attachedto the nozzle assembly, the nozzle assembly is thereby rotated, but at areduced speed that is determined by the amount of the reduction providedby the reduction gear train.

Alternatively, the drive mechanism may include a stepper motor coupledto the transmission in place of the turbine. Unlike the turbine, astepper motor provides a constant rotational drive source which iseasily electrically controlled. However, such a stepper motor is locatedwithin the sprinkler body, and typically is positioned within the waterflow path in the riser. Consequently, the motor housing and the relatedwires protruding from the housing must be waterproofed to prevent waterrelated motor malfunction.

Further, sprinklers (including a motorized sprinkler) typically rely onmechanical watering arc adjustments located on the sprinkler to controlwhich areas a sprinkler head rotates through when watering.Consequently, a user must mechanically set each arc adjustment at eachsprinkler location. Since an irrigation system may have many sprinklers,determining and setting individual sprinkler arcs at each sprinkler sitecan consume a large amount of time, especially if the irrigation systemis installed over a large area such as a golf course.

Another feature of many prior art sprinklers is the use of electricallyactuated pilot valves which connect inline with the irrigation watersupply and a sprinkler, allowing the water flow to an individualsprinkler to be turned on or off, preferably from a distant centralcontrol system. Typically, these pilot valves are located partially oreven completely outside the sprinkler body. Thus, when the pilot valveneeds adjustment or replacement, a user must shut off the water supplyleading to the pilot valve, dig around the sprinkler to find the pilotvalve, replace the pilot valve, rebury it, then turn the water supplyback on. Since the main water supply must be shut off, other sprinklerswill not function during this time consuming repair and may interruptpreprogrammed watering cycles.

Although the prior art sprinklers discussed above have been known tooperate with general satisfaction, there is always a need to pursueimprovements. For example, prior art sprinklers do not always providethe desired accuracy in rotating the nozzle. Nor do they typically offereasy ways to maintain or repair the sprinkler. Nor do they offer theuser a way to remotely control or remotely reconfigure the sprinkler. Inthese and other respects, therefore, the prior art sprinklers are knownto have substantive limitations.

What is needed is a motorized sprinkler that senses the position of theriser nozzle, allowing the watering arc to be modified at a distantlocation. What is also needed is a sprinkler having a waterproof motorhousing to prevent water related damage to the sprinkler motor. Further,what is needed is a sprinkler that incorporates external sprinklercomponents, such as a pilot valve, within the sprinkler body for easyaccess during repair and replacement.

OBJECTS AND SUMMARY OF THE INVENTION

It is an object of the present invention to overcome the above statedlimitations of the prior art.

It is a further object of the present invention to provide a motorizedsprinkler with a waterproof motor housing.

It is yet a further object of the present invention to provide amotorized sprinkler system wherein the vertical position of the riserand the arc position of the nozzle can be sensed remotely.

It is yet a further object of the present invention to provide amotorized sprinkler that allows its watering arc to be modified at adistant location.

It is a further object of the present invention to provide an improvedsprinkler body design, including integrally molded sprinkler bodycompartments.

It is an object of the present invention to provide an easily removablepilot valve that is located internal to the sprinkler body compartment.

The above stated objects are achieved with the present invention whichincludes an improved sprinkler design including a magnetic sensingsystem for determining the elevation and angular position of the nozzle,a waterproofed motor housing and related cables, configurable sprinklerbody compartments, and a pilot valve with a check valve assembly, bothof which are located within the sprinkler body compartment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a side view of a sprinkler according to the presentinvention;

FIG. 1B illustrates a top view of the sprinkler of FIG. 1A;

FIG. 2 illustrates a flow chart of a magnetic sensing sprinkleraccording to the present invention;

FIG. 3A illustrates a graph of magnetic sensor data of a magneticsensing sprinkler according to the present invention;

FIG. 3B illustrates a graph of magnetic sensor data of a magneticsensing sprinkler according to the present invention;

FIG. 4A illustrates a graph of raw rotational magnetic sensor dataaccording to the present invention;

FIG. 4B illustrates a graph of normalized magnetic sensor data accordingto the present invention;

FIG. 4C illustrates a graph of rotational angle data according to thepresent invention;

FIG. 5 illustrates a cutaway view of the sprinkler of FIG. 1A;

FIG. 6 illustrates a cutaway view of the sprinkler of FIG. 1A;

FIG. 7 illustrates a cutaway view of the sprinkler of FIG. 1A;

FIG. 8 illustrates a cutaway view of a portion of the sprinkler of FIG.1A;

FIGS. 9A-9B illustrate a cutaway view of a check valve according to thepresent invention;

FIG. 10A illustrate a cutaway view of a check valve according to thepresent invention;

FIGS. 10B-10C illustrates a side view of a valve member of the valve ofFIG. 10A;

FIGS. 11A-11 b illustrate a cutaway view of a check valve according tothe present invention;

FIGS. 12A-13 illustrate a cutaway view of a motor housing according tothe present invention;

FIG. 14 illustrates a top view of the sprinkler of FIG. 1A;

FIG. 15 illustrates a perspective view of a waterproof motorcommunication connector according to the present invention;

FIG. 16 illustrates a perspective view of an alternate preferredembodiment of a single attachable body compartment according to thepresent invention;

FIGS. 17 and 18 illustrates a side view of an alternate preferredembodiment of a check valve and pilot valve nozzle tip valve accordingto the present invention;

FIGS. 19-21 illustrates a side view of an alternate preferred embodimentof a check valve and pilot valve nozzle tip according to the presentinvention;

FIGS. 22-23 illustrates a side view of a valve according to the presentinvention;

FIGS. 24A-24D illustrates a perspective view of an alternate preferredembodiment of a motor housing plate according to the present invention;

FIGS. 25A-25C illustrate a motor housing plate according to the presentinvention;

FIG. 26 illustrates a perspective view of a single compartment floor fora sprinkler according to the present invention; and

FIG. 27 illustrates a perspective view of a unitary sprinklercompartment floor according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides an improved sprinkler having a motorizedriser with magnetic position sensing and a waterproof motor housing.These features allow the sprinkler to send riser position data to acentral computer control system and, in turn, to accept control signalsback from the computer control system determining the desired wateringarc for that sprinkler.

The present invention also provides a sprinkler body with additionalbody compartments adjacent the sprinkler body wall. These compartmentsmay be configurable in size and shape to accept a variety of differentsprinkler related equipment which have traditionally not been includedwithin the sprinkler body. Also, each compartment may be easilyaccessible by opening a top lid on the sprinkler body.

Finally, the present invention includes a pilot valve configured withina sprinkler body compartment, also including an inline check valve.Since the pilot valve is located within a body compartment, the pilotvalve is easily accessible for maintenance. Ease of repair is furtherincreased by a check valve that allows the pilot valve to be removedfrom the sprinkler without first shutting down the main water supply.

Irrigation Sprinkler with Position Sensing

Referring to FIGS. 1A and 1B, a sprinkler 100 is shown according to thepresent invention, having a magnet 108 positioned in the sprinklernozzle assembly 103 of the riser assembly 105 and a magnet sensor 114located in an electronic assembly 110 of the sprinkler body 102. Notethat the riser assembly 105 includes riser 104 and nozzle assembly 103.Generally, the magnet sensor 114 senses the strength of the magneticfield as the magnet 108 moves towards and away (both rotationally andlinearly up and down) from the magnetic sensor 114, allowing amicroprocessor 107 within the irrigation sprinkler 100 to detect therotational position, speed of rotation, direction of the nozzlerotation, and longitudinal position of the riser 104.

The magnet 108 is positioned at the upper-most portion of the riser 106,preferably extending substantially the entire diameter across the riser106. Thus, the magnet 108 rotates with the sprinkler riser 106, varyingthe magnetic fields immediately around the riser 106. A known pole ofthe magnet, for example North, is positioned inline with, and orientedtowards the nozzle 101 of the nozzle assembly 103, associating a knownmagnetic field value with the nozzle 101 for reference in determiningthe rotational angle of the nozzle 101 during operation.

The magnet 108 is preferably a dipole magnet, having predominant Northand South poles. A Ceramic 8 material magnet is preferred; however amagnet with similar properties may also be used.

The magnet sensor 114 is located near the top of an electronic assembly110 of the sprinkler body 102, but may also preferably be located withinan upper, sealed region of the sprinkler body itself. Preferably, a twoaxis magneto-restrictive sensor such as a HMC1052 model manufactured byHoneywell is used for the magnet sensor 114, although a wide range ofsimilar sensors may be used, so long as they have the necessarysensitivity to detect the magnetic field fluctuation.

The magnet sensor 114 is connected to a microprocessor 107 located inthe electronic assembly of sprinkler body 102 or alternatively in aremote location, which accepts magnetic field data sensed by the magnetsensor 114. The microprocessor 107 then calculates the position of thenozzle 101 of the nozzle assembly 103 (e.g. angular position and “poppedup” or retracted position) so that this position data may be relayed toa central controller.

The sprinkler 100 preferably has an electric stepper motor (described infurther detail below) which rotates the nozzle assembly 103, allowing adesired area around the sprinkler to be watered. However, other methodsof rotating the nozzle assembly 103 may be used, such as traditionalturbine driven mechanisms with an electrically controlledrotation-reversing switch.

As seen in the flow chart of FIG. 2, the position sensing processes 261according to one embodiment of the present invention generally comprisesa microprocessor component 262 (i.e. the microprocessor 107) whichaccepts electrical power from a power component 263, command signalsfrom a communication component 268 and magnetic sensing data from amagnetic sensing component 260 (e.g. magnetic sensor 114). Theelectrical power allows the microprocessor component 262 to operate,while the communication component 268 sends data and command signalsbetween the microprocessor component 262 and a remote sprinklercontroller (not shown). The magnetic sensing component 260 provides rawsensor data to the microprocessor component, which the microprocessorcomponent 262 in turn analyzes. Finally, the microprocessor component262 sends control signals to the solenoid driver component 270 (e.g.solenoid 162) causing the sprinkler 100 water flow to activate ordeactivate (respectively raising or lowering the riser), and also sendscontrol signals to the stepper motor component 266 (e.g. stepper motor212) which causes the nozzle assembly 103 to rotate. As the steppermotor component 266 operates, the magnetic sensor component 260 sendsdata reflecting a change in position of the nozzle assembly 103 to themicroprocessor component 262. This sensor data is again analyzed by themicroprocessor component 262 and command signals are again sent out tothe stepper motor component 266 accordingly to manipulate the positionof the nozzle assembly 103. In this respect, a feedback loop is createdwithin the sprinkler 100.

In operation, a microprocessor 107 within the electronic assembly 110communicates with a central irrigation controller (not shown) todetermine the watering program for that individual sprinkler 100. Thatwatering program will include requirements for the arc the sprinkler 100should rotate, the length of time watering should occur, the time atwhich to start watering as well as other relevant watering instructions.When the microprocessor 107 reads the watering program and determinesthat the sprinkler 100 should activate, a calibration cycle isinitialized by rotating the nozzle assembly 103 in a complete circle andmeasuring the magnetic field data with magnet sensor 114. Thisrotational calibration provides the magnetic sensor 114 with thestrongest and weakest magnetic signals in both the X and Y axes, whichallows the microprocessor to then calculate the angular position of thenozzle 101.

It is desired that no water exit the nozzle 101 when calibrating, so asto prevent water from being inadvertently sprayed in an unwantedlocation. Thus, the nozzle assembly 103 may be calibrated in a loweredposition prior to activation of the sprinkler pilot valve 150 (seen inFIGS. 5, 6, and 8 and described in further detail below). Note thatcalibration may also occur when the riser 104 and nozzle assembly 103are in a raised position with an alternate sprinkler design thatincludes a second motor for raising and lowering both components withoutopening the pilot valve 151.

FIG. 3A illustrates example magnetic field signals in the X and Y axisdirection for a nozzle assembly 103 continuously rotating in a“popped-up” position. By directing one axis of the two axis magnetsensor 114 towards the axis of rotation of the nozzle assembly 103, theX and Y axis readings form sinusoidal waves that are offset by 90degrees as nozzle assembly 103 rotates. Measuring both the X axis andthe Y axis, the nozzle 101 angle can be mathematically determined orcompared against reference data, allowing the microprocessor toaccurately execute a watering program, including a desired watering arc.

FIG. 3B illustrates example magnetic field signals for a riser 104 andnozzle assembly 103 in a raised and lowered position. Note that when theriser 104 is in a lowered position, the magnet 108 is closer to themagnet sensor 114, thus producing stronger magnetic field signals thanin a raised position. The microprocessor 107 may have various magneticfield value thresholds preprogrammed, allowing the microprocessor 107 todetect the position of the nozzle assembly 103 when a magnetic fieldvalue passes a threshold. For example, the microprocessor 107 could havepreprogrammed upper and lower thresholds which indicate the riser 104 isin fully risen or fully retracted position. Further, if the riser 104 isnot in a fully risen or fully retracted position, the microprocessor 107calculates the position of the riser 104 and alerts a user elsewhere toa potential sprinkler 100 malfunction.

In a specific example of the present embodiment, the two axis magnetsensor 114 is placed off axis of the nozzle assembly 103 and magnet 108,as seen in FIG. 1B. One sensing axis of the two-axis magnet sensor 114is pointed at the axis of rotation of the magnet 108 which allows themagnetic field data collected from the magnet sensor 114 to form an Xand Y sinusoidal wave, 90 degrees out of phase, as seen in FIG. 3A. Themagnetic field values obtained by the magnet sensor 114 are normalized,then compared to a set of normalized reference values (which could be assimple as using the arc tan function available in many microprocessorprogramming languages), allowing the microprocessor 107 to determine therotational position of magnet 108 in reference to the sprinkler body 102and magnetic north.

An initial calibration phase may be performed upon installation or priorto activation, which generally includes collecting raw reference dataand various correction factors which will later be applied to this rawreference data. Initially during this calibration phase, the magnetsensor 114 determines the zero magnetic field value (the X-Y sensorvalues that correspond to a state of zero X and Y magnetic fields).

Next, the magnet sensor 114 generates raw magnetic field reference databy rotating the nozzle assembly 103 360 degrees and recording the data.Alternatively, this reference data may be obtained by rotating thenozzle assembly 103 through a portion of the rotational arc of thenozzle assembly 103 and mathematically extrapolating the additionaldata. For illustrative purposes, example raw reference data has beenplotted on an X-Y graph in FIG. 4A, and forms an overall ellipse shape.

At this point, the microprocessor 107 has determined a raw data set andthe zero magnetic field value. Next, a refined reference data set isdetermined, as seen in FIG. 4B, by centering, rotating, and normalizingthe raw reference data set.

The raw data is centered by first calculating the center of this ellipseshape (seen in FIG. 4A) and is normalized by adjusting all referencedata points so the ellipse center is now zero along both axes. Theellipse center may be calculated, for example, by a “least squares fit”technique. Since the Earth's magnetic field offsets each X-Y magneticfield data point by the same amount, the center of the ellipse alsorepresents the value of the Earth's magnetic field. Once this value isfound, all raw reference data points are shifted so that the ellipsecenter is 0 along both axes, seen in FIG. 4B.

Next the raw data is rotated. Ideally, the raw reference data set willnot need to be rotated and the major and minor curves of the ellipsewill fall directly on the X or Y axis. However, a slight misalignment ofthe magnet sensor 114 axis pointed towards the axis of rotation of thenozzle assembly 103 may often occur due to imperfections in the magnetsensor 114, soldering of the magnet sensor 114 to a circuit board, orother physical misalignments. These physical misalignments cause avirtual misalignment of the ellipse reference data from the X and Yaxes, as seen in FIG. 4A. FIG. 4B illustrates this reference data in arotated orientation with the major and minor curves along the X and Yaxes. For example, this rotation may be performed by adjusting all ofthe reference data points so the highest/lowest values possible of thedata line up along the X and Y axes.

Once the major and minor diameters align with the X and Y axes, the datais normalized by dividing the X and Y values for each point by half ofthe major and minor diameters of the ellipse, respectively. A “leastsquares fit” technique may be used on raw data points that representeither a full circle or partial circle and will yield, simultaneously,the ellipse center, the rotation angle, and the major and minor angle.As the reference data set becomes larger, the more accurate these valvescan be determined using this technique.

Thus, FIG. 4B illustrates the “adjusted” data which has been centered,rotated, and normalized. When non-reference data is acquired by themagnet sensor 114, it is “adjusted” by the same process as described forthe reference data. (The process was applied to the reference data justto prove that it accomplished what was intended, which is to map eachpoint onto (very near to) the unit circle. The angle of a point on thecircle relative to the X axis is equal to the angle of the nozzlerelative to the position of the sensor, which is fixed relative to thebody. The whole purpose of the reference data is to determine theellipse center, the rotational misalignment of the sensor, and the majorand minor diameters of the ellipse so the any data point can be mappedonto the unit circle. Since the X and Y values of the “virtual” point atthe center of the ellipse correspond to the Earth's magnetic field, wecan calculate the angle between the sensor and magnetic North. Thenadding this angle to the angle ((as determined above) between the nozzleand the sensor yields the angle of the nozzle relative to magneticNorth.)

Finally, a reference point must be determined between the reference dataof FIG. 4B and the real physical world. In the case of the sprinklerbody 102, this may be accomplished by preprogramming the microprocessorwith reference thresholds relating to a specific position, such asaligning the body with a landmark during installation or by measuringthe angle between the body and some landmark (even magnetic North) afterinstallation, and then manually entering this data (this process couldbe automated with the correct auxiliary equipment). Thus, the positionof the magnet 108 (and therefore the nozzle 101) is known relative tothe magnetic sensor 114 (and therefore the body 102) whose position isknown relative to the real physical world.

In addition to the sprinkler body 102 reference point, the Earth'smagnetic North may be used as an alternative or additional referencepoint. The value and direction (i.e. the vector) of the Earth's magneticfield relative to the sensor may be determined by creating a vectorbetween the zero magnetic field point and the center of the ellipse,both of which can be seen in FIG. 4A. By adding this angle to the angleof the nozzle relative to the sensor as calculated above, themicroprocessor 107 may calculate angle between the magnet 108 and theEarth's magnetic North.

This positional difference from magnetic North may be utilized with aremotely located sprinkler controller for sprinkler 100 orientationpurposes. For example, the sprinkler controller may record the anglebetween magnetic North and a reference point on the sprinkler body 102.When this value changes, the position or orientation of sprinkler body102 has been reoriented (for example by a maintenance crew, by vandalsor mechanical malfunction), which may send a warning to the user andpossibly deactivate that particular sprinkler 100, preventing damagefrom undesired irrigation. In a similar manner, the arc limits can bereferenced against magnetic North, to determine if one of the arc limitshas slipped. For example, if one reference angle value between magneticNorth and an arc setting changes, but the other arc setting has notchanged, a user may be alerted by the central controller that one of thearc settings has slipped or malfunctioned. Alternately, a recalibrationcould be performed. This would determine what the actual currentorientation of the body is and if the arc limits are still acceptable.If the arc is correct but the arc limits have changed, the whole bodywas rotated. If the arc has changed, but it is known that it needed tobe adjusted, the adjustment will be verified to be correct. If the arcis incorrect, the sprinkler needs to be serviced. At this point, theuser knows of the potential problem, and can decide what parts and toolsneed to be taken to the site.

Additionally, the magnetic North reference point may be sent to acentral sprinkler controller which correlates the magnetic Northreference point, the nozzle assembly 103 position data, physicalsprinkler position data, and a geographic map to provide a sprinklercontrol map. This sprinkler control map may illustrate the location ofeach sprinkler 100 on a geographic map, as well as the direction eachsprinkler 100 is currently watering.

FIG. 4C illustrates a graph of example data of the rotation degrees ofmagnet 108 verses time. Specifically, this example data illustrates themagnet 108 rotating in continuous circles. Using this information, themicroprocessor 107 may determine the speed and direction of rotation ofthe nozzle assembly 103. This riser data may be communicated to acentral controller, allowing a user to monitor and ultimately controldifferent aspects of the sprinkler nozzle assembly 103 and sprinkler 100performance. For example, a user may remotely monitor the position androtational speed of the nozzle 101 of nozzle assembly 103 and decide tomodify the rotational speed of the nozzle assembly 103.

Once the calibration has finished and the position of the nozzle 101 hasbeen determined, the microprocessor executes the watering program,watering within a desired arc radius for a determined amount of time.For example, the nozzle 101 can be directed by the watering program tocomplete a desired number of complete traverses of the arc to bewatered, therefore providing a more even watering pattern. Whencomplete, the microprocessor shuts off the water flow to the nozzle 101,lowering the riser 104. Preferably, the nozzle 101 is returned to aspecific known angle to allow the calibration for the next wateringcycle to be performed more predictably. Additionally, returning to aspecific known angle provides more uniform water coverage since thewatering cycle may be stopped after a full arc sweep, instead of only aportion of a desired watering arc.

For example, this even watering arc could be performed by sensing theposition of the nozzle 101 when a “stop” signal is sent to thesprinkler. If the nozzle 101 is not at one end of the set watering arc,the nozzle 101 continues to irrigate until the nozzle assembly 103reaches one of the set watering arc ends. Alternatively, themicroprocessor 107 may adjust the speed of nozzle assembly 103 rotationto allow a whole number of sweeps through a desired watering arc duringa desired watering time. Thus, at the end of the watering cycle, thenozzle 101 will be angled at an end of the watering arc and an equalamount of water will have been delivered to the turf within thesprinkler 100 watering arc, including during the beginning and end ofthe watering cycle.

It should be noted that the magnetic field of the Earth or various metaldeposits below the ground may alter the magnetic field data obtained bythe magnet sensor 114. However, in most cases calibration of thesprinkler will overcome any such magnet sensor 114 variations.

Although the above described embodiment is a preferred method ofachieving the present invention, other preferred embodiments arepossible without departing from the present invention. For example, aHall effect sensor may be used as the magnet sensor 114.

In another preferred embodiment of the present invention (not shown), aplurality of switches are positioned around the nozzle assembly 103within the stationary portion of sprinkler 100 as a single trigger onthe nozzle assembly 103 rotates along with the nozzle assembly 103,turning each switch on or off as it passes. These signals are thendetected by the microprocessor 107 and, with the help of a timer device(not shown) translated into a rotational speed.

The angular position of the nozzle 101 of the nozzle assembly 103 may bedetermined by allowing the microprocessor 107 to count the number oftimes a switch has been actuated as the nozzle assembly 103 rotates.This allows the microprocessor 107 to determine the initial startingposition. As the nozzle assembly 103 rotates during the normal course ofoperation, the microprocessor 107 counts the subsequent switchactuations and, depending on the number of switchers, calculates theangular position of the nozzle 101. Alternatively, each switch may bepreprogrammed to correlate to an angular position of the nozzle 101 (orother reference point) and the overall orientation of the sprinkler 100may be installed at a known relative orientation.

The switches may be magnetic “pickup” switches, light emittingcomponents (e.g. LED's and light detectors), mechanical switches, orother switches. Preferably, the switches for determining rotation arepositioned to potentially activate when the riser 104 and nozzleassembly 103 are in a fully risen position, allowing the switches toswitch as the nozzle assembly 103 rotates.

To detect the vertical position of the riser 104, yet another switch ismounted to the sprinkler 100 body to detect the position of any of thetriggers on the nozzle assembly 103 body.

In another preferred embodiment of the present invention (not shown), asingle switch may be positioned within the sprinkler 100 while aplurality of triggers or pickups may be positioned on the nozzleassembly 103. In this embodiment, each trigger sends a different signalback to the microprocessor 107 which then determines the direction ofthe nozzle 101, the speed of rotation of the nozzle 101, and the heightof the nozzle assembly 103 in a similar fashion to the previouslydescribed embodiment.

In summary, the detection and monitoring of the angular and verticalposition of the nozzle 101 through the use of the use of the onboardmicroprocessor 107 allows the use of feedback control of the sprinkler100 with the central controller. This offers a far more versatilesprinkler system insofar as each sprinkler 100 can be individuallyprogrammed and controlled for precise watering. For example, the samesprinkler 100 can be used for two different turf sections that may havedifferent watering needs.

Sprinkler Body with Compartments

Referring now to FIGS. 1A, 1B, and 14, a plan view of the sprinkler body102 can be seen according to the present invention, having bodycompartments 240. These body compartments are located within the outersection of sprinkler body 102 for containing sprinkler components thatare not by design located on the inside of the main body of thesprinkler 100. Thus, these components may be accessed by simply removingthe sprinkler cover 248, instead of digging such components up from theground as prior art models required.

The body compartments 240 have compartment walls 242 integrally moldedwith the sprinkler body 102 and a separate removable compartment floorwhich is preferably attached to the body compartment walls 242 withfasteners. Such separately manufactured compartment floors 250 allow forvarious configurations to fit different components installed into thecompartments without disturbing or affecting the compartmentconfiguration or manufacturing process. Thus, previously installedsprinklers may be modified with a different compartment floor to allowfor installation of various components that would not fit the originalcompartment floor 250.

Optionally, the compartment floor 250 may be integrally molded as partof the bottom of the compartments. Such a unitary molded part reducescosts associated with having multiple body compartments, as well asreduces the reject rate associate with the reduction of manufacturingsteps.

Alternately, the body compartments 240 may preferably be created byindividually molded compartment inserts 242 a, as seen in FIG. 16. Thecompartment inserts 242 a may be attached to the exterior wall ofsprinkler body 102 through mechanical fastening, bonding, ultrasonicwelding, or other fastening methods and may have varying sizes,encompassing different radial portions of the outer sprinkler body 102.As seen in FIG. 16, these inserts preferably have a locking groove 241,allowing the user to slide the inserts 242 a in place. These compartmentinserts 250 may optionally have individual compartment floors 250 a, asseen in FIG. 26, or utilize a single compartment floor 250 b in common,as seen in FIG. 27.

Prior art sprinklers often incorporated a “flange” at the top of thebody to prevent lateral movement in the ground and to reduce downwardsinking into the dirt due to pressure from yard equipment riding overthe sprinkler body. As seen in FIGS. 1A, 5, 6, and 7, the bodycompartments 240 may not extend the entire length of the sprinkler 100.This creates a narrowed region underneath the body compartments 240. Thebottom area of the compartments therefore acts as a mechanism to preventsinking, providing lateral support normally associated with the flange.

Check Valve

Turning now to FIGS. 5-7, a check valve 151 is illustrated according tothe present invention which allows a sprinkler pilot valve 150 to beremoved from a sprinkler 100 without shutting down the irrigation watersupply of the sprinkler 100. When the pilot valve 150 is removed fromthe sprinkler 100, the check valve 151 maintains the main valve cylinder168 in a closed position, preventing water-flow though the sprinkler100.

Typically, pilot valves are used to actuate a water supply to anirrigation sprinkler, thus serving as an “on” or “off” switch. Suchpilot valves are commonly connected to irrigation water conduitsupstream of the sprinkler or integrated into the sprinkler as seen inthe commonly owned and currently pending U.S. patent application Ser.No. 10/774,705, filed Feb. 9, 2004, entitled Sprinkler System and inU.S. patent application Ser. No. 10/789,862, filed Feb. 27, 2004,entitled Low Flow Valve Improvement, of which the contents of bothapplications are hereby incorporated by reference. Often, pilot valveshave a solenoid which may be electrically actuated by way of low voltageelectrical current. This electrical activation allows water flow to asprinkler to be turned on from a remote location, such as, for exampleby according to a watering program of an irrigation controller.

As seen best in FIGS. 6 and 8, a pilot valve 150 typically is connectedto a main valve cylinder 168 through a communication tube 160. The valvecylinder 168 has valve seals 170, which form a sealed chamber within thevalve cylinder 168. The main valve cylinder 168 prevents the flow ofwater into the sprinkler 100 when in a lowered position so that thevalve bottom 166 presses against valve seat 172. Alternately, water flowinto the sprinkler 100 is no longer prevented when the main valvecylinder 168 moves to a raised position, lifting the valve bottom 166away from the valve seat 172.

The raised or lowered position of the main valve cylinder 168 iscontrolled by varying the pressure within the main valve cylinder 168.An increased pressure within the main valve cylinder 168 holds the valvebottom 166 against the valve seat 172 in a lowered, closed state, whilereduced or no relative pressure within the main valve cylinder 168allows the valve bottom 166 to be pushed upwards to an open state by thewater coming into the sprinkler.

A metering pin 164 allows a small volume of water into the main valvecylinder 168 through a gap 174 between the metering pin 164 and the mainvalve cylinder 168. With water entering the main valve cylinder 168,pressure within the main valve cylinder 168 increases.

The communication tube 160 connects the inside of the main valvecylinder 168 to the check valve 151 and ultimately on to a pressurerelieving mechanism 153 controlled by the solenoid 162, seen best inFIG. 6. When the pressure relieving mechanism 153 is closed, pressurebuilds within the main valve cylinder 168. When the solenoid 162 isenergized and the pressure relieving mechanism 153 vents, pressure isrelieved within the main valve cylinder 168, allowing the valve bottom166 to be pushed upwards to an open state by the incoming water supply.

As previously stated, the check valve 151 allows a user to remove thepilot valve 150 from a sprinkler 100 without the need to shut down thewater supply upstream of the pilot valve 150. As best seen withreference to FIGS. 6 and 8, the check valve 151 is generally locatedbetween the main valve cylinder 168 and the pilot valve 150. Thecommunication tube 160 connects the inner chamber of the main valvecylinder 168 with the check valve 151, while the check valve 151 isconnected to the pilot valve 150. Thus a continuous passage links theinner chamber of the main valve cylinder 168 with the pilot valve 150.

The check valve 151 is composed of four main elements: check ballretainer 158, check ball 156, spring 157 and check valve housing 154.The check ball 156 is positioned within the check valve housing 154while the check ball retainer 158 is located at the bottom portion ofthe check valve housing 154. In this manner, the check ball retainer 158prevents the check ball 156 from falling out of the check valve 151 whenthe check valve 151 is removed for repair or replacement. The spring 157provides a biasing pressure on the check ball 156, pressing the checkball 156 against the flanged portion 154 a of check valve housing 154when the check valve 151 closes. A nozzle tip 152 of the pilot valve 150fits within the top aperture of the check valve housing 154, forming atight seal between both. Additionally, an O-ring 149 is positionedaround the nozzle tip 152 so as to contact the check valve housing 154.The check valve 151 seals prior to hydraulically releasing the O-ring149 and opens after the nozzle tip 152 and the O-ring 149 hydraulicallyengage the top aperture of the check valve housing 154. For example, thedistance between the flanged portion 154 a and the O-ring 149 is equalto or greater than the distance between the check ball 156 and theflanged portion 154 a in an open position. Thus, as the nozzle tip 152is pulled upward, the check ball 156 seals against the flanged portion154 a before the hydraulic seal between the top aperture of the checkvalve housing 154 and the nozzle tip 152 with the O-ring 149 is broken.In this respect, water is prevented from escaping when the nozzle tip156 is removed.

Referring to FIGS. 5-8, in operation, water from an irrigation watersupply flows into the sprinkler 100. Some of this water then flows intothe inner chamber of the main valve cylinder 168 through the gap 174created by metering pin 164. Once inside the inner chamber of the mainvalve cylinder 168, the water continues on through the communicationtube 160, to the check valve 151 where it pushes the check ball 156upward within the check valve housing 154. If the nozzle tip 152 of thepilot valve 150 is positioned within the check valve housing 154, thecheck ball 156 will press against the nozzle tip 152, but will not blockfurther passage of the water into the pilot valve 150. Thus, the pilotvalve 150 is free to create or relieve pressure to operate the mainvalve cylinder 168 as previously described.

However, if the nozzle tip 152 is removed from the check valve housing154, i.e. if the pilot valve 150 is removed from the sprinkler 100 (e.g.for servicing or repair), the check ball 156 presses against a flangedportion 154 a within the check valve housing 154, creating a seal whichblocks water passage out of the top aperture of the check valve housing154. Thus, the check valve 151 maintains water pressure within the mainvalve cylinder 168 when the nozzle tip 152 is removed from the checkvalve 151, preventing the main valve cylinder 168 from allowing water topass into the main portion of sprinkler 100. Thus, when a user desiresto remove the pilot valve 150 from the sprinkler 200, the irrigationwater supply to the sprinkler 100 may be left on and the pilot valve 150may simply be removed, since the check valve 151 will prevent the mainvalve cylinder 168 from opening and spraying water from the nozzle ofthe sprinkler 100.

The spring 157 may optionally be included between the check ball 156 andthe check ball retainer 158, biasing the check ball 156 up against theflanged portion 154 a of the check valve housing 154. Thus, even whenthere is little or no water pressure, the check valve 151 will be biasedclosed unless otherwise opened by the nozzle tip 152. The spring 157also assists in assuring that the ball 156 seats against the flangedportion 154 a of the check valve housing 154, as the ball 156 may, attimes, not seat due to low differential water pressure and thereforecontinue to flow when the nozzle tip 152 is removed.

Although, check valve 151 utilizes a check ball 156, other embodimentsare possible according to the present invention. For example thealternative preferred embodiments of FIGS. 9A and 9B illustrate a checkvalve 180 having a flexible leaflet valve 182, which is enclosed withinthe check valve housing 154. The leaflet valve 182 is hinged to openonly towards the inlet of the check valve housing 184. Thus, waterentering the check valve 180 force the leaflet valve 182 closed. As seenin FIG. 9B, the nozzle tip 152 of the pilot valve 150 pushes the leafletvalve 182 open, allowing water to flow through to the pilot valve 150.

FIGS. 10A-10C illustrate yet another alternative preferred embodiment ofa check valve 190 according to the present invention, having a duck billvalve 194 within check valve housing 192. The duck bill valve 194 ispositioned with the flexible bill section 194 a towards the inlet of thecheck valve 190. Water entering the check valve 190 is unable to passthe duck bill valve 194 since the water pressure forces the duck billvalve 194 closed. The duck bill valve 194 opens when the nozzle tip 152is inserted into the check valve 190, and further into the duck billedvalve 194, opening the valve and allowing water to pass into the pilotvalve 150.

Turning now to FIGS. 11A-11B, a check valve 196 is illustrated accordingto the present invention, having a conical valve member 198 positionedwithin the check valve housing 197. The smaller diameter end of conicalvalve member 198 is angled towards the outlet of check valve housing197, while the larger diameter end is angled towards the inlet of checkvalve housing 197. The water pressure pushes the conical valve member198 against the angled inner flange 197 a in check valve housing 197,closing the check valve 196. As with previously described embodiments,the nozzle tip 152 of pilot valve 150 is inserted into the check valve190, moving the conical valve member 198 away from the angled innerflange 197 a, thus opening check valve 196 to allow water to flow intothe pilot valve 150.

Preferably, the nozzle tip 152 of the pilot valve 150 is configured toprevent water from exiting the check valve 151 when the nozzle tip 152is inserted or removed from the check valve 151. This shape ensures thatthe main valve cylinder 168 remains completely closed, preventing theriser 104 from popping up and even small amounts of water from sprayingout of the nozzle 101 of the sprinkler 100. The nozzle tip 152 isconfigured such that water is allowed to enter through the center of thenozzle tip 152, even when the nozzle tip is pressed against the checkball 156 when inserted within the check valve housing 154. FIGS. 19-21illustrate one preferred design of a nozzle tip 264, having an archingwater entry port 264 a. Even when the check ball 156 is pressed againstthe bottom of nozzle tip 264, water may still pass into the nozzle tip264 and further into the check valve 151. FIG. 20 illustrates the checkvalve housing 154 without the nozzle tip 264 engaged. FIGS. 18, 22 and23 illustrate a similar nozzle tip 260 design, having a circular waterport 260 a which allows the water to enter the tip despite being pressedagainst the check ball 156.

FIGS. 17 and 18 illustrate another embodiment of a check valve 261 ofthe present invention, including a disk 262 composed of resilientmaterial and a stem 262 a which is centrally located and downwardlyangled from the disk 262. The disk 262 seats against the flanged area154 a of the check valve housing 154 when the nozzle tip 152 is removedfrom the check valve 151. The spring 157 contacts the disk 262, therebybiasing it upwards against the flanged area 154 a to a closed position.The check valve 261 is opened when the nozzle tip 152 pushes the disk262 downward, against the bias of spring 157, which allows water to flowinto the nozzle tip 152 and into the pilot valve 150.

Rigid Communication Tube

Turning now to FIGS. 5-8, a communications tube 160 is shown accordingto the present invention, constructed from a rigid material such asstainless steel, but may be made of any rigid metal or plastic materialimpervious to corrosion. Since the communications tube 160 may belocated at least partially outside the sprinkler 100, the rigid natureof the tube 160 protects the communications tube 160 from damage.

As described elsewhere in this application, the communication tube 160connects the inner chamber of the main valve cylinder 168 with the checkvalve 151 or alternately directly to the pilot valve 150 if a checkvalve 151 is not included with the sprinkler 100. Prior artcommunication tubes are typically composed of a flexible material whichrequires the tubes to be connected to barbed connectors. Such flexiblecommunication tubes remained vulnerable to damage from handling andespecially to tools used to move dirt, e.g. a shovel. In addition to theflexible tube, many additional parts, as well as labor, was required forproper installation of the communication tube.

The communication tube 160 simplifies the prior art tubes by eliminatingthe number of additional parts and assembly steps needed forinstallation, while providing additional integrity to the communicationtube 160. The communication tube 160 is configured to connect the checkvalve 151 with the main valve cylinder 168 as a single angled component,closely following the sprinkler 100 body.

As seen in FIGS. 5-8, preferably, a rigid rib 200 fills the spacebetween the communication tube 160 and the sprinkler 100 body. The rib200 is molded to the shape of the communication tube 160, providingadditional support and stability. Also, walls (not shown) may beincluded along the sides of the communication tube 160 for additionallateral support.

Optionally, the communication tube 160 may include a plastic thread,molded to the end of the communication tube 160. This plastic threadallows the communication tube to removably connect to the check valve151 for repair or replacement. The check valve housing 154 incorporatesan internal thread that mates with the threaded portion molded aroundthe communication tube 160. This allows the check valve housing 154 tobe connected to, and removed from, the communication tube 160 easily,thereby facilitating its repair and replacement.

Motor and Gear Train Housing

Referring now to FIGS. 7, 12A, 12B, 13, 14, 15 and 24A-24D a sealedmotor housing 213 that also houses a motor 212 for use in the sprinkler100 of the present invention is shown. Moreover, the motor 212 is showncoupled to a gear train 214. The sealed motor housing 213 is positionedabove the screen 176, allowing water to flow through water tube 210,around the sealed motor housing 213 and out through the nozzle 101 whenthe sprinkler 100 is in operation. However, the sealed motor housing 213prevents this water flow from leaking inside to the stepper motor 212and gear train 214.

A top portion 214 a of gear train 214 protrudes from a top aperture ofsealed motor housing 213, interlocking with nozzle assembly 103 torotate the nozzle 101 during sprinkler 100 operation. The top apertureof the sealed motor housing 213 is sealed with an O-ring 218 positionedbetween the top portion 214 a of gear train 214 and the inner surface ofthe sealed motor housing 213.

Integral with the bottom of sealed motor housing 213 is a connector endplate 220 and connector receptacle 220 a, having a cable port 238 whichaccepts a mating cable connector assembly 230, seen in FIGS. 15 and 24,at the end of electrical cable 216. This electrical cable 216 ultimatelyconnects to an electronics module 244 (seen in FIG. 14) located in abody compartment 240 of the sprinkler 100, external to the water flowpath. Since the cable connector assembly 230 provides a removablewaterproof connection to the stepper motor 212, simple disconnection andremoval of the motor housing 213 is facilitated.

Referring to FIGS. 15 and 24A-24D, the cable connector assembly 230connects to the cable port 238 in the connector end plate 220 in asealed, water-tight manner, being composed of a connector jack 232,overmolding 234, and a connector O-ring 236 or integrally molded sealingrings. Preferably, a telephone-style RJ-11 jack is used as the connectorjack 232 in cable connector assembly 230, although a variety ofdifferent connector jacks 232 may be used.

The overmolding 234 is preferably composed of a resilient syntheticmaterial (e.g. PVC or Santoprene) configured to enclose the connectorjack 232 on all sides except at the end of the connector jack 232. Theovermolding 234 has an O-ring 236 (or optionally multiple O-rings 236)composed of a compliant sealing material which may be used inconjunction with a waterproof gel (not shown) around the O-ring 236 andin the inner space 238 within the overmolding 234.

When the cable connector assembly 230 is connected to the cable port 238on the connector plate 220, the O-ring 236 on the overmolding 234presses against the connector plate 220, creating a water-tight sealpreventing the inflow of water within the overmolding 234. Thewaterproof gel further enhances the seal created by the O-ring 236 andthe connector plate 220, ensuring that no water comes in contact withthe electrical pins 209 within the connector assembly 230.

On the inner side of the connector plate 220, seen best in FIG. 24D,connecting pins 211 protrude from the connector plate 220, creating anelectrical connection from the cable port 238 to the inside of the motorhousing 213. A small cable, not shown, connects to these pins 211 tomotor 212, providing power and communications data.

Alternatively, the O-ring 236 may be formed of an integral unitaryportion of overmolding 234 and may also include multiple O-ring 234shapes to enhance waterproofing of the cable connector assembly 230. Inplace of O-rings 234, more resilient “blade” shapes or “chevron seals”may also be used, molded in conjunction with the overmolding 234.Further, such O-rings 236 or blade shaped protrusions may be fixed orintegral with the cable port of the connector end plate 220.

FIGS. 25A-25C illustrates another embodiment of the present invention,having an alternate connector plate 220 b having an integralnon-removable cable 216 a, lacking a connector assembly. One end of thecable 216 a is connected to the motor 212 on the inside of the motorhousing 213, while the other end is connected to the electronics thatdrive the motor 212. The cable 216 a is sealed to the end plate 220 b bystrain relief seal 215, such that water does not pass between the cable216 a and the seal 215. Preferably, the cable 216 a is “integrallymolded” into the end plate 220 via the seal 215, providing greaterassurance that a leak path between the cable 216 a and the end plate 220b is not present.

Although the invention has been described in terms of particularembodiments and applications, one of ordinary skill in the art, in lightof this teaching, can generate additional embodiments and modificationswithout departing from the spirit of or exceeding the scope of theclaimed invention. Accordingly, it is to be understood that the drawingsand descriptions herein are proffered by way of example to facilitatecomprehension of the invention and should not be construed to limit thescope thereof.

What is claimed is:
 1. A sprinkler.